Method of making a composite gear

Abstract

A method of manufacturing a tool used to make a composite gear, the method including forming a cavity in a plate, the cavity being partially defined by a surface in the plate. The surface has a plurality of tool teeth. The method further includes machining at least some of the tool teeth such that some tool teeth have opposed first and second side sections and a central section disposed between the first and second side sections. The central section is larger than the side sections in a circumferential direction. The method further includes creating at least one centering protrusion on the surface. Preferably, the cavity forming step includes forming an aperture in the plate and electric discharge machining the surface of the cavity using a current carrying wire. The machining step preferably includes orbiting an electrode in a first position of the cavity to create the first side section and orbiting the electrode in a second position of the cavity to create the second side section. The creating step preferably includes creating two centering protrusions on opposite sides of at least some of the tool teeth.

What is claimed is: 
     
       1. A method of manufacturing a tool used to make a composite gear, comprising: forming a cavity in a plate, said cavity being partially defined by a surface in said plate, said surface having a plurality of tool teeth;   machining at least some of said tool teeth such that said some tool teeth have opposed first and second side sections and a central section disposed between said first and second side sections, said central section being larger than said side sections in a circumferential direction; and   creating at least one centering protrusion on said surface.   
     
     
       2. The method of claim 1, wherein said cavity forming step includes: forming an aperture in said plate; and   electric discharge machining said surface of said cavity using a current carrying wire.   
     
     
       3. The method of claim 1, wherein said machining step includes: orbiting an electrode in a first portion of said cavity to create said first side sections; and   orbiting said electrode in a second portion of said cavity to create said second side sections.   
     
     
       4. The method of claim 3, further comprising: passing said electrode through said cavity before said first orbiting step.   
     
     
       5. The method of claim 1, wherein said creating step includes: creating two centering protrusions on opposite sides of at least some of said tool teeth.   
     
     
       6. The method of claim 1, further comprising: tapering said at least one centering protrusion.   
     
     
       7. The method of claim 1, wherein said tapering step includes: applying an electrode to said at least one centering protrusion.   
     
     
       8. A method of manufacturing a tool used to make a composite gear, comprising: forming a cavity in a plate, said cavity being partially defined by a surface in said plate, said surface having a plurality of tool teeth, said forming step including forming an aperture in said plate;   electric discharge machining said surface using a current carrying wire;     machining at least some of said tool teeth such that said some tool teeth have opposed first and second side sections and a central section disposed between said first and second side sections, said central section being larger than said side sections in a circumferential direction, said machining step including orbiting an electrode in a first portion of said cavity to create said first section;   orbiting said electrode in a second portion of said cavity to create said second section; and     creating at least one centering protrusion on at least one of said tool teeth.   
     
     
       9. The method of claim 8, further comprising: tapering said centering protrusion.   
     
     
       10. The method of claim 9, wherein said tapering step includes: applying a second electrode to said centering protrusion.